ToolPath Generation for Foam Project - How would you do it?! LD45

[chris_g_mcghee]

Hola! 🙂

Looking for some advice on the best toolpath for this project attached. 

Material - Plastazote LD45

EndMill - Sorotec Z3 6mm

Firstly I should state - in a perfect world I would firstly follow the outside line of the pocket with varying Z from the model, with an offset of 0.5mm giving a crisp clean outer cut for when the pocket is complete. 

Then I would use a toolpath that cuts the internal -> out with the option of both ways travel as the external cut is already completed - I mean logically thats probably illogical so I'm trying to do it with the same size endmill as I am only a hobbyist, and would like to avoid constant  tool changing. 

I state this as currently these cuts are extremely long passes this causes me problems - possibility of the foam cuts wrapping around the tool piece which tends to happen on the last of the passes so its always the external walls that are damaged. 

Both way travel for clearing internally is fine - but the external cuts must be conventional to ensure clean edges hence the initial cut request.

I'm just seeking advice / how would you do this - I'm entirely self taught fusion, and just think maybe I'm at that stage I really need advice going. 

Hope you can all help would be much appreciated ❤️

ps. YES when you view my current toolpaths in the file - there are stepovers of 5.5mm this is huge on time it reduces estimation from like 45 to 15min, this foam does not require intricate step overs when using 3D / 2D adaptive and it always leaves edge looking terrible and I have had no success using rest machining to adaptively clear - then do the external clean up without it machining the whole part (air cutting) until edge is touched)

[programming2C78B · Accepted solution]

"follow the outside line of the pocket with varying Z"
Use 2D contour with a ramp angle

I'd do this with a Pocket or Flat toolpath.

[chris_g_mcghee]

Flat toolpath with or without spirals passes are tooling causing long lengths of cut foam with chance to wrap around end mill. 

Albeit after posting this I went off on a read of the fusion documents found a picture of all things, so took a different approach. 

Used the tool 3D model that were used to cut the pockets out as the pieces to reference toolpaths against. 

Then used 2D contour with offset, and then 2d Adaptive. 

Cleanest cuts most reliable cuts so far. Super happy. Thanks for your advice 2c78b but all sorted 👍🏻